Electrical box brace

ABSTRACT

An electrical box brace including a rod, a sleeve, at least one mounting plate, an adjustment mechanism having a body, a spring and connecting the rod and sleeve, and at least one engagement device positioned within the adjustment mechanism body, wherein the at least one engagement device includes at least one threaded portion opposite a ramp, and wherein the ramp selectively engages the adjustment mechanism body to permit engagement or disengagement of the at least one threaded portion with the rod.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to currently pending U.S. patentapplication Ser. No. 14/641,355, filed on Mar. 7, 2015 and titledELECTRICAL BOX BRACE to Baldwin et al., which will issue as U.S. Pat.No. 10,008,842 on Jun. 26, 2018, the disclosure of which is herebyincorporated herein by reference. This application claims priority tocurrently Provisional U.S. Patent Application No. 61/951,534, filed onMar. 12, 2014 and titled CEILING FAN BOX BRACE to Baldwin et al., thedisclosure of which is hereby incorporated herein by reference.

BACKGROUND

Electrical boxes are well known and have been used for decades inbuildings. Electrical boxes are used both in walls and ceilings toprovide electrical current to various places within a building. Further,the electrical boxes may also be used to mount various electricalreceptacles, such as duplex or decorator outlets, or electricalswitches. In ceilings, electrical boxes function to support the weightof the light fixture or ceiling fan in addition to providing electricalcurrent to operate the light and/or fan.

Electrical boxes can be installed in a number of different ways. In newconstruction, the electrical boxes are mounted directly to studs ortrusses and then drywall is mounted. In retrofit applications, theelectrical box is mounted to drywall instead of the studs. In ceilingfan box retrofit installations the ceiling fan box must be mounted tothe studs or other suitable structure so that the ceiling fan weight maybe properly supported during fan operation.

SUMMARY

Aspects of this disclosure relate to electrical box braces. In oneaspect, an electrical box brace includes a rod, a sleeve, at least onemounting plate, an adjustment mechanism connecting the rod and thesleeve, and wherein the adjustment mechanism permits at least two ratesof relative movement between the rod and the sleeve.

In an implementation, the adjustment mechanism may be a threaded insert.The threaded insert may be spring biased in a closed position. Therelative movement between the rod and the sleeve may be slower when thethreaded insert is biased in the closed position. The relative movementbetween the rod and the sleeve may be faster when the threaded insert isin the open position. The threaded insert may include at least twothreads. The threaded insert may further include an angled surface. Theadjustment mechanism may further include an angled surface, whereinengagement between the angled surfaces compresses the threaded insert.

The threaded insert may include at least two inserts, one insertincluding a threaded portion and the other insert does not include athreaded portion. The first rate of relative movement may be in theaxial direction and the second rate of relative movement may berotational movement. The rotational movement may be slower than theaxial movement. The adjustment mechanism may include a spring steelclamping mechanism. An electrical box may be permanently or removablysecured to the brace. The electrical box may be a ceiling fan box. Theaxial movement may be permitted in a first direction and not permittedin a second direction opposite the first direction.

In another aspect, an electrical box brace includes a rod havingthreaded portions, a sleeve to receive the rod, an adjustment mechanismpositioned in the sleeve, a mounting plate on an end of the sleeve, amounting plate on the end of the rod, and wherein the adjustmentmechanism selectively permits rotational or axial movement between therod and the sleeve.

In another aspect, a method of mounting an electrical box includes thesteps of positioning the electrical box brace between joists, pulling asleeve and a rod in opposite directions until a mounting plate on eachof the sleeve and the rod contacts each joist, and rotating the sleeveor rod to further displace the mounting plates.

In an implementation, the method may include the step of moving anadjustment mechanism to an open position during the pulling step. Themethod may include the step of moving the adjustment mechanism to aclosed position before the rotating step.

Aspects and applications of the disclosure presented here are describedbelow in the drawings and detailed description. Unless specificallynoted, it is intended that the words and phrases in the specificationand the claims be given their plain, ordinary, and accustomed meaning tothose of ordinary skill in the applicable arts. The inventors are fullyaware that they can be their own lexicographers if desired. Theinventors expressly elect, as their own lexicographers, to use only theplain and ordinary meaning of terms in the specification and claimsunless they clearly state otherwise and then further, expressly setforth the “special” definition of that term and explain how it differsfrom the plain and ordinary meaning. Absent such clear statements ofintent to apply a “special” definition, it is the inventors' intent anddesire that the simple, plain and ordinary meaning to the terms beapplied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar.Thus, if a noun, term, or phrase is intended to be furthercharacterized, specified, or narrowed in some way, then such noun, term,or phrase will expressly include additional adjectives, descriptiveterms, or other modifiers in accordance with the normal precepts ofEnglish grammar. Absent the use of such adjectives, descriptive terms,or modifiers, it is the intent that such nouns, terms, or phrases begiven their plain, and ordinary English meaning to those skilled in theapplicable arts as set forth above.

The foregoing and other aspects, features, and advantages will beapparent to those artisans of ordinary skill in the art from theDESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will hereinafter be described inconjunction with the appended drawings, where like designations denotelike elements, and:

FIG. 1 is a perspective view of an electrical box brace.

FIG. 2A is an enlarged view of the electrical box brace mounting end andthread.

FIG. 2B is an enlarged view of the electrical box brace mounting end.

FIG. 2C is an exploded view of an adjustment mechanism.

FIG. 3 is a side view of the adjustment mechanism.

FIG. 4 is a front view of the adjustment mechanism.

FIG. 5 is a rear view of the adjustment mechanism.

FIG. 6 is a sectional view of the adjustment mechanism taken generallyabout line 6-6 in FIG. 4.

FIG. 6A is an enlarged view of the portion labeled 6A in FIG. 6.

FIG. 7 is a sectional view of the adjustment mechanism.

FIG. 8 is a side view of a second adjustment mechanism.

FIG. 9 is a front view of the second adjustment mechanism.

FIG. 10 is a sectional view of the second adjustment mechanism.

FIG. 11 is a sectional view of a third adjustment mechanism.

FIG. 12 is a front view of a fourth adjustment mechanism.

FIG. 13 is a sectional view of the fourth adjustment mechanism in afirst position and taken generally about line 13-13 in FIG. 12.

FIG. 14 is a sectional view of the fourth adjustment mechanism in asecond position and taken generally about line 13-13 in FIG. 12.

FIG. 15 is a sectional view taken generally about line 15-15 in FIG. 12.

DETAILED DESCRIPTION

This disclosure, its aspects and implementations, are not limited to thespecific components or assembly procedures disclosed herein. Manyadditional components and assembly procedures known in the artconsistent with the intended operation and assembly procedures for anelectrical box brace will become apparent for use with implementationsof an electrical box brace from this disclosure. Accordingly, forexample, although particular components are disclosed, such componentsand other implementing components may comprise any shape, size, style,type, model, version, measurement, concentration, material, quantity,and/or the like as is known in the art for such implementing components,consistent with the intended operation of an electrical box brace.

FIGS. 1-7 illustrate various views of a first aspect electrical boxbrace 10 having a sleeve 12 and a rod 14. Rod 14 may be threaded withany suitable thread dimensions or pitches, as well as multiple threadpitches on a single rod. An adjustment mechanism 16 includes a face 18and may be positioned in sleeve 12 for engagement with rod 14. Mountingplates 20 are positioned on each of sleeve 12 and rod 14. Each mountingplate may include at least one curved engagement tooth 22 and/or atleast one straight tooth 24 which each engage or grip a joist or otherappropriate mounting structure. Further, each mounting plate 20 mayinclude a mounting aperture 26 arranged to be secured to the rod 14 orsleeve 12 via threaded engagement, screws, nuts, rivets, or any othersuitable mechanism such that a mounting face 28 of the mounting platecontacts the joist or other mounting structure upon installation.

A ceiling fan box or electrical box 30 may be secured to the sleeve 12or rod 14 with clamps 32 or other known and suitable connecting devicesincluding rivets, screws, or the like. In operation, electrical boxbrace 10 provides at least two different rates of relative movementbetween the rod and the sleeve as will be described in more detailbelow. In a first rate of relative movement, the rod and sleeve aremoved in the direction associated with arrow 36 to quickly expand thedistance between the mounting plates by pulling the mounting plates 20apart from each other. In a second rate of relative movement, rotatingthe sleeve 12 or rod 14 in the direction associated with arrows 34increases or decreases the distance between the mounting plates but at arate slower than the first rate of relative movement. Still further,movement in the direction associated with arrow 38 is generally onlyaccomplished as a resultant of rotation in the direction associated witharrows 34 as axial movement of the mounting plates towards one anotheris resisted by the adjustment mechanism, but axial movement of themounting plates away from one another is generally permitted.

Moving to FIGS. 2A and 2B, sleeve 12 may include an end cap 40 having anend cap tongue 42 with an aperture 44 for securing the end cap in thesleeve 12. A stop 46 and a head 48 work in conjunction with apertures 26in mounting plates 20. In this structure, stop 46 can rotate freelyagainst the back of mounting plate 20 and head 48 may be compressed orriveted within aperture 26 such that the mounting plate 20 can besecured to the sleeve 12 and rod 14 to mount the electrical box bracebetween joists or other suitable mounting structures but still rotateabout the rod or the sleeve if desired.

FIG. 2C is an exploded view of a first adjustment mechanism 16. Body 52includes face 18, an upper and lower engagement member slot 54, and arod opening 56 passing through the entire body 52. Moving briefly tosleeve 12, an opening 58 therein is arranged to receive a spring 60 andto secure body 52 within the opening 58. The opening 58 may include anappropriate attachment mechanism to secure the adjustment mechanism 16within the sleeve 12 at opening 58.

An engagement device 62 includes a body 63 having a first end 64 with aterminating portion 66 and a ramped portion 68. Further, a threadedportion 70 may be positioned near or overlapping ramped portion 68. Asecond end 72 may include a wall with a closing wall 74 forming aretaining region 76 there between which may be used to secure spring 60therein.

As seen in FIG. 3, spring 60 is engaged between body 52 and retainingregion 76. In this manner, spring 60 biases the engagement devices 62away from body 52 in the normal state so that the threaded portions 70are engaged with thread valleys 15 and thread peaks 17 and permit onlyrotational movement for the second rate of relative axial movement whilenot allowing the first rate of relative axial movement when the springis expanded.

FIG. 6 illustrates the adjustment mechanism 16 with the spring 60contacting end 78 of body 52 which forces ramped portion 68 into ramps67 of body 52. The ramped portion 68 engagement with ramps 67 ensuresthat threaded portions 70 engage with thread valleys 15 or thread peaks17. Again, in this aspect and manner only rotational movement can permitthe slower rate of axial movement between the mounting plates.

FIG. 7 illustrates the electrical box brace 10 during a first rate ofrelative movement with the sleeve 12 and the rod 14 being pulled axiallyapart from each other in the direction associated with arrow 84. As therod 14 and sleeve 12 are separated in this direction, spring 60 iscompressed and the ramped portion 68 permits the engagement devices 62to move away from the rod 14 in the directions associated with arrows 80and 82. Accordingly, rod 14 can be quickly separated from the sleeve 12and provide fast axial movement and thus coarsely align the mountingplates between the joists in a ceiling or wall. When pressure in thedirection of arrows 84 is removed, spring 60 forces the engagementdevices 62 back against the ramped portion 68 to re-engage theengagement devices 62 with the rod 14. At this point, the user canrotate the rod 14 or sleeve 12 to provide further relative moment at aslower axial rate due to the rotation, but provide more torque to drivethe mounting plates into the joists.

FIGS. 8-10 illustrate a second aspect engagement mechanism 16 havingonly a single engagement device 62 therein. Spring 60 engages tabs 78 onengagement device 62 and a thicker rear wall 90 on a bottom portion 86of engagement mechanism 16 and particularly body 52. Still further, aninterior wall 88 of body 52 permits rod 14 to pass through andengagement with the single engagement device 62 provides thefunctionality described above but accomplished with only one engagementdevice instead of two.

FIG. 11 illustrates a third aspect engagement mechanism 16 having thesame functionality and features as previously disclosed aspects.Specifically, tab 78 may be recessed within in interior wall 88 from theend and a recess 92 may be positioned opposite tab 78 which is arrangedto receive spring 60 therein. In this orientation, spring 60 may bebetter secured within the engagement member for more consistentoperation. Still further, threads 89 may be positioned on bottom portion86 and interior wall 88. Nevertheless, the operation and functionalityremains the same, even with fewer threaded portions on engagement device62.

FIGS. 12-15 illustrate various views of a fourth aspect engagementmechanism 94 which may be made from a spring steel or other suitablematerial. Engagement mechanism 94 may include engagement tabs 96 havingan end 106 for contacting thread valleys 15. Engagement mechanism 94 mayalso include curved ends 98 with side walls 104 and bendable joints 102connecting the side walls 104 and engagement tabs 96. FIG. 13illustrates the end 106 contacting the rod 14 and which prevents the rod14 from moving into the engagement mechanism 94. FIG. 14 shows rapidmovement due to axial separation of rod 14 and sleeve 12 moving relativeto one another. Specifically, rod 14 is moved in the directionassociated with arrow 108 which forces ends 106 in the directionassociated with arrows 110 due to the angled arrangement of engagementtabs 96. Accordingly, once the axial movement in the direction of arrow108 stops, ends 106 are repositioned within thread valleys and axialmovement in the direction opposite arrow 108 is prevented. Nevertheless,rotational relative movement can occur in either direction which resultsin axial movement to expand or contract the distance between the twomounting plates once the ends 106 are repositioned within threadvalleys. Accordingly, the user can rapidly expand the distance betweenthe mounting plates in a single direction and then reduce the distancebetween the mounting plates by rotating the rod or sleeve in a firstdirection and further expand the distance between the mounting plates byrotating the rod or sleeve in a second direction opposite the firstdirection.

Still further, as seen in FIG. 15, engagement mechanism 94 is securedwithin sleeve 12 with tabs 100 which may extend through a portion ofsleeve 100. As can be seen, the engagement mechanism 94 provides anefficient and reliable way to significantly reduce the installation timeof an electrical box brace because coarse and rapid movement isaccomplished without impact the ability to provide a high torque fineengagement between the rod and the sleeve.

In operation, the electrical box brace is expanded from a first positionto a second position by axially extending or pulling the sleeve and therod apart from each other at the adjustment mechanism. During thisoperation, the adjustment mechanism moves from a first closed positiondue to a spring bias to a second open position where the spring isovercome and the threads are disengaged. Once an approximate distance isreached, the tension on the spring is released and the threads are onceagain engaged. When the threads are engaged, rotation may occur tofurther expand the electrical box brace mounting plate distance andprovide the ample torque necessary to engage the joists with themounting plates. Still further, axial movement may be prevented tocontract the electrical box brace and may require rotational movementbetween the rod and the sleeve. In all aspects, an aspect may be toprovide at least two speeds to relative movement, wherein one of therates is significantly faster and easier than the other rates.

It will be understood that implementations are not limited to thespecific components disclosed herein, as virtually any componentsconsistent with the intended operation of a method and/or systemimplementation for an electrical box brace may be utilized. Componentsmay comprise any shape, size, style, type, model, version, class, grade,measurement, concentration, material, weight, quantity, and/or the likeconsistent with the intended operation of a method and/or systemimplementation for an electrical box brace.

The concepts disclosed herein are not limited to the specificimplementations shown herein. For example, it is specificallycontemplated that the components included in a particular implementationof an electrical box brace may be formed of any of many different typesof materials or combinations that can readily be formed into shapedobjects and that are consistent with the intended operation of anelectrical box brace. For example, the components may be formed of:rubbers (synthetic and/or natural) and/or other like materials; polymersand/or other like materials; plastics, and/or other like materials;composites and/or other like materials; metals and/or other likematerials; alloys and/or other like materials; and/or any combination ofthe foregoing.

Furthermore, embodiments of the electrical box brace may be manufacturedseparately and then assembled together, or any or all of the componentsmay be manufactured simultaneously and integrally joined with oneanother. Manufacture of these components separately or simultaneouslymay involve extrusion, pultrusion, vacuum forming, injection molding,blow molding, resin transfer molding, casting, forging, cold rolling,milling, drilling, reaming, turning, grinding, stamping, cutting,bending, welding, soldering, hardening, riveting, punching, plating,and/or the like. If any of the components are manufactured separately,they may then be coupled or removably coupled with one another in anymanner, such as with adhesive, a weld, a fastener, any combinationthereof, and/or the like for example, depending on, among otherconsiderations, the particular material(s) forming the components.

In places where the description above refers to particularimplementations of an electrical box brace, it should be readilyapparent that a number of modifications may be made without departingfrom the spirit thereof and that these implementations may be applied toother electrical box braces. The accompanying claims are intended tocover such modifications as would fall within the true spirit and scopeof the disclosure set forth in this document. The presently disclosedimplementations are, therefore, to be considered in all respects asillustrative and not restrictive, the scope of the disclosure beingindicated by the appended claims rather than the foregoing description.All changes that come within the meaning of and range of equivalency ofthe claims are intended to be embraced therein.

We claim:
 1. An electrical box brace comprising: a rod; a sleeve; atleast one mounting plate; an adjustment mechanism having a body, aspring and connecting the rod and sleeve, and at least one engagementdevice positioned within the adjustment mechanism body; wherein the atleast one engagement device includes at least one threaded portionopposite a ramp, the at least one threaded portion and the ramppositioned on a first end of the at least one engagement device, the atleast one engagement device comprising a second end comprising aretaining region formed between the second end and a closing wall; and,wherein the ramp selectively engages the adjustment mechanism body topermit engagement or disengagement of the at least one threaded portionwith the rod.
 2. The electrical box brace of claim 1 wherein the atleast one engagement device is two engagement devices.
 3. The electricalbox brace of claim 2 wherein the two engagement devices are position onopposite sides of the rod.
 4. The electrical box brace of claim 2wherein the engagement devices do not contact one another duringoperation.
 5. The electrical box brace of claim 1 wherein an electricalbox is secured to the electrical box brace.
 6. The electrical box braceof claim 1 wherein an electrical box is removably secured to theelectrical box brace.
 7. The electrical box brace of claim 1 wherein theat least one mounting plate is a mounting plate rotatably mounted to anend portion on each of the sleeve and the rod.
 8. The electrical boxbrace of claim 1 wherein the spring is positioned within the retainingregion.
 9. The electrical box brace of claim 1 wherein the adjustmentmechanism body further comprises at least one ramp.
 10. The electricalbox brace of claim 9 wherein the at least one adjustment mechanism bodyramp is two ramps positioned opposite each other.
 11. The electrical boxbrace of claim 9 wherein the at least one adjustment mechanism body rampengages the at least one engagement device ramp.
 12. The electrical boxbrace of claim 1 wherein the threaded portion further comprises fivethreads.
 13. An electrical box brace comprising: a rod; a sleeve; atleast one mounting plate; an adjustment mechanism having a body, aspring and connecting the rod and sleeve, and at least one engagementdevice positioned within the adjustment mechanism body; wherein the atleast one engagement device includes at least one threaded portionopposite a ramp, the at least one threaded portion and the ramppositioned on a first end of the at least one engagement device, the atleast one engagement device comprising a second end comprising aretaining region with the spring positioned within the retaining region;and, wherein the ramp selectively engages the adjustment mechanism bodyto permit engagement or disengagement of the at least one threadedportion with the rod.